Charging cover detection structure and method based on pressure sensor

Abstract

The invention provides a charging cover detection structure and method based on a pressure sensor, and belongs to the technical field of building outer wall facade facing layer defect monitoring. The charging cover detection structure comprises a charging cover and a jack base, the jack base is movably connected with the charging cover through a hinge, and a semicircular convex block is arranged on the front face of the charging cover; the top of the front face of the jack base is provided with a bayonet matched with the protruding block, the bottom of the interior of the bayonet is provided with a charging cover switch, and the charging cover switch is fixed to the bottom of the bayonet through a screw. Physical disconnection of the charging gun and circuit residual signals can be effectively distinguished, and particularly under the situation that the charging gun is disconnected but a CC resistor still exists, auxiliary judgment of the pressure signals ensures that the connection state is accurately recognized, and safe starting of a vehicle is guaranteed.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of building exterior wall facade defect monitoring, and particularly relates to a charging cover detection structure and method based on a pressure sensor. BACKGROUND

[0002] With the improvement of the technological level, new energy electric vehicles have also developed rapidly. At present, new energy electric vehicles in China have become one of the world's leading industries. About 90% of new energy electric vehicles are electric vehicles, and these electric vehicles all need to be supplied with electric energy through charging piles. After charging is completed, the user must manually disconnect the charging gun operation to start the vehicle. The vehicle detects the CC resistance to detect whether the charging gun is disconnected. When the CC resistance cannot be detected, it means that the charging gun is disconnected; otherwise, it is considered that the charging gun is in a connected state. However, this scheme has the possibility of misjudgment of the charging gun. If the charging gun has been disconnected, but the CC resistance is detected, the vehicle cannot be in a high-voltage state or respond normally, which affects the user experience and may cause safety hazards. The priority of the user's demand for the connection state detection of the charging gun is high-precision detection, fast response, non-destructive operation, environmental adaptability, and low misjudgment rate. However, the existing technology mainly relies on single CC resistance detection, and there is a significant difference between performance and demand.

[0003] Modern electric vehicles have higher requirements for the safety management of charging interfaces, especially reliable detection in frequent charging and complex environments. However, the existing charging gun disconnection detection technology faces the following key technical problems:

[0004] Limited environmental adaptability: The existing CC resistance detection method is greatly affected by environmental factors such as high temperature, humidity, and electromagnetic interference. For example, under high humidity (> 80%) or low temperature (<-10℃) conditions, the resistance signal may drift, resulting in a misjudgment rate as high as 15%. Single detection lacks environmental correction mechanism, and it is difficult to adapt to cross-season or extreme weather (such as heavy rain and strong wind), which limits the reliability and applicability of detection.

[0005] Low intelligence and automation: The current detection system is mainly a single resistance module, which lacks integrated control and data processing capability and relies on manual operation and basic circuit judgment. For example, resistance detection needs to be combined with manual inspection of the charging gun state, and the detection time is long (30-60 seconds / time), which cannot realize automation. The existing system lacks real-time data fusion and intelligent diagnosis function, and the user needs to frequently manually verify, which is low in maintenance efficiency.

[0006] High risk of misjudgment: the existing technology only relies on CC resistance and cannot effectively distinguish between physical disconnection of the charging gun and residual signals in the circuit, resulting in a high false positive rate (about 10%-15%). Especially when the CC resistance is still detected due to poor contact or residual charge after the charging gun is disconnected, the vehicle may misjudge that it is in a connected state, limiting high-voltage activation and affecting the convenience of use.

[0007] Therefore, there is a need for a charging cover detection structure and method based on a pressure sensor to solve the above problems. SUMMARY

[0008] Technical problems solved

[0009] In view of the deficiencies of the prior art, the present application provides a charging cover detection structure and method based on a pressure sensor, which solves the problems mentioned in the above background art.

[0010] Technical solutions

[0011] To achieve the above purpose, the present application is implemented by the following technical solutions: a charging cover detection structure based on a pressure sensor, comprising a charging cover and a jack base, the jack base is movably connected with the charging cover through a hinge, the front surface of the charging cover is provided with a semicircular protrusion, the top of the front surface of the jack base is provided with a bayonet that is mutually adapted with the protrusion, a charging cover switch is installed at the bottom of the bayonet, and the charging cover switch is fixed to the bottom of the bayonet through screws; a circular ring-shaped sealing gasket is clamped in the inside of the jack base, and the sealing gasket is connected with the inner wall of the jack base through buckles.

[0012] Preferably, piezoelectric pressure sensors are installed at both sides of the sealing gasket near the bottom, the piezoelectric pressure sensors are fixed and embedded in the sealing gasket through wires, and the surface of the sensor is flush with the sealing gasket; seven contacts are provided at the bottom of the jack base, the seven contacts are respectively a vehicle socket contact, a control guide CP, a neutral line N, an alternating current power supply L1, an alternating current power supply L2, an alternating current power supply L3, and a protective grounding PE, and the contacts are fixed to the bottom of the jack base through welding and distributed in a circular array.

[0013] Preferably, a temperature compensation module is further provided in the jack base, the temperature compensation module comprises a thermistor, is installed on the inner wall of the jack base through an adhesive method, is connected to a data acquisition system, has a temperature compensation range of-20℃ to 60℃, and an error is controlled within ±0.1℃.

[0014] Preferably, a dustproof film is provided between the charging cover and the jack base, the dustproof film is made of waterproof and breathable material, is fixed around the bayonet through adhesive, is pressed tightly by the protrusion when the charging cover is closed, and the sealing effect is ensured.

[0015] Preferably, the jack base is provided with a power management module, the power management module is fixed on the bottom of the jack base by screws, adopts low-power design to supply power for the piezoelectric pressure sensor and the charging cover switch, has overvoltage protection and short circuit protection functions, the working voltage range is 5V to 12V, and the standby power consumption is lower than 10mW.

[0016] Preferably, the jack base is installed on the vehicle charging interface position through fastening bolts, during installation, the jack base is ensured to be flush with the vehicle shell, and the sealing gasket is tightly attached to the closed surface of the charging cover, and after installation is completed, waterproof test is carried out.

[0017] Preferably, the piezoelectric pressure sensor is connected to the vehicle control system through a data acquisition system, during installation, the wire is protected by a waterproof sleeve, the signal transmission distance between the sensor and the data acquisition system is not more than 1 meter, and the signal stability is ensured.

[0018] Preferably, the charging cover is connected to the jack base through a hinge, the hinge is made of stainless steel material, during installation, anti-rust oil is applied, the convex block cooperates with the socket when the charging cover is closed, and the closing signal is triggered by the charging cover switch.

[0019] A charging cover detection method based on a pressure sensor, the detection method comprises a pressure signal acquisition process, a signal processing process, a charging gun state judgment process and an adaptive correction process; the pressure signal acquisition process acquires the pressure signals FN1 and FN2 generated when the charging cover is closed in real time through two piezoelectric pressure sensors and transmits the pressure signals to a data acquisition system; the signal processing process converts the pressure signals into voltage signals by using a DLF series channel charge amplifier, carries out filtering and standardization processing by using a DASP signal analyzer, and dynamically corrects the temperature influence in combination with a temperature compensation module; the charging gun state judgment process comprehensively judges according to the CC resistance detection result and the pressure signals: if the CC resistance is not detected and the two piezoelectric pressure sensors 7 do not detect the pressure signals, the charging gun state is disconnected; if the CC resistance is not detected but any sensor detects the pressure signal, the charging gun state is disconnected; if the CC resistance is not detected and the two sensors detect the pressure signals, the charging gun state is connected; if the CC resistance is detected and any sensor detects the pressure signal, the charging gun state is connected; if the CC resistance is detected and the two sensors do not detect the pressure signals, the charging gun state is disconnected; the adaptive correction process updates the pressure threshold value every 72 hours through historical data analysis, reduces environmental interference, improves the detection accuracy, and when the charging gun state is disconnected, the vehicle control system allows switching to a high-voltage state.

[0020] Beneficial effects

[0021] The application provides a charging cover detection structure and method based on a pressure sensor.

[0022] Advantages:

[0023] 1. The present application significantly improves the detection accuracy and reliability: through the dual detection mechanism of piezoelectric pressure sensor and CC resistance, the present application can effectively distinguish the physical disconnection of charging gun and the residual signal of circuit, especially in the case of charging gun disconnection but CC resistance still exists, the auxiliary judgment of pressure signal ensures accurate identification of connection state, and guarantees the safe start of vehicle. In addition, the buffer design of sealing gasket protects the sensor from direct external force damage, further improves the long-term stability and reliability of the system, and solves the misjudgment problem caused by single resistance detection in the prior art.

[0024] 2. The present application enhances environmental adaptability and operational convenience: equipped with temperature compensation module, the present application corrects the sensor sensitivity in real time through thermistor in the temperature range of-20℃ to 60℃, adapts to high humidity environment and extreme weather (such as heavy rain, strong wind), and overcomes the limitations caused by environmental drift of single CC resistance detection. At the same time, the optimized signal processing process (DLF amplifier + DASP analysis) realizes millisecond-level fast response, cooperates with automatic judgment function, eliminates the cumbersome steps of manual inspection, and greatly improves the operational convenience of users in complex environment.

[0025] 3. The present application reduces maintenance cost and improves intelligent management: sealing gasket and dustproof film provide IP67 waterproof and dustproof protection, the contact adopts gold plating design to prolong the service life, combined with low power consumption (<10mW) power management module, reduces the cost burden caused by environmental erosion or frequent maintenance. In addition, through adaptive correction and double sensor series design, the present application dynamically updates the pressure threshold every 72 hours, and switches to standby mode (depends on CC resistance) when the sensor fails, ensuring that the system can still maintain partial functions under single point failure, realizing intelligent management and fault tolerance, which is significantly superior to the lack of redundancy of the prior art. BRIEF DESCRIPTION OF DRAWINGS

[0026] Figure 1 is the detection process diagram of the present application;

[0027] Figure 2 is the charging port schematic diagram of the present application;

[0028] Figure 3 is the socket base schematic diagram of the present application;

[0029] Figure 4 is the charging cover closed schematic diagram of the present application;

[0030] Figure 5 is the working principle schematic diagram of piezoelectric sensor of the present application;

[0031] Figure 6The schematic diagram of the new energy electric vehicle charging gun test system of the present aspect.

[0032] Legend:

[0033] 1, charging cover; 2, jack base; 3, charging cover switch; 4, bayonet; 5, contact; 6, protrusion; 7, pressure sensor; 8, sealing gasket. DETAILED DESCRIPTION

[0034] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application. Specific embodiment one:

[0036] As shown in Figures 1 to 6 A charging cover detection structure based on a pressure sensor, comprising a charging cover 1 and a jack base 2, the jack base 2 is movably connected with the charging cover 1 through a hinge, the front of the charging cover 1 is provided with a semicircular protrusion 6, the top of the front of the jack base 2 is provided with a bayonet 4 which is mutually adapted with the protrusion 6, a charging cover switch 3 is installed in the bottom of the bayonet 4, and the charging cover switch 3 is fixed to the bottom of the bayonet 4 through a screw; a circular sealing gasket 8 is clamped in the inside of the jack base 2, and the sealing gasket 8 is connected with the inner wall of the jack base 2 through a buckle.

[0037] Piezoelectric pressure sensors 7 are installed on both sides of the sealing gasket 8 close to the bottom, the piezoelectric pressure sensors 7 are fixed and embedded in the sealing gasket 8 through wires, the surface of the sensors is flush with the sealing gasket 8; seven contacts 5 are provided on the bottom in the jack base 2, the seven contacts 5 are respectively a vehicle socket contact, a control pilot CP, a neutral wire N, an alternating current power supply L1, an alternating current power supply L2, an alternating current power supply L3 and a protective earth PE, and the contacts 5 are fixed on the bottom of the jack base 2 through welding and distributed in a circular array.

[0038] A temperature compensation module is further provided in the jack base 2, the temperature compensation module comprises a thermistor which is installed on the inner wall of the jack base 2 through an adhesive method and connected to a data acquisition system, the temperature compensation range is-20℃ to 60℃, and the error is controlled within ±0.1℃.

[0039] A dustproof film is provided between the charging cover 1 and the jack base 2, the dustproof film is made of waterproof and breathable material and fixed around the bayonet 4 through adhesive, and the charging cover 1 is pressed tightly by the protrusion 6 when closed, so as to ensure the sealing effect.

[0040] The power management module 11 is arranged in the jack base 2, is fixed to the bottom of the jack base 2 through a screw, supplies power for the piezoelectric pressure sensor 7 and the charging cover switch 3 by adopting a low-power design, has overvoltage protection and short-circuit protection functions, and has a working voltage range of 5V to 12V and standby power consumption lower than 10mW.

[0041] The jack base 2 is installed at a charging interface position of a vehicle through a fastening bolt, and during installation, the jack base 2 is ensured to be flush with a vehicle shell, the sealing gasket 8 is tightly attached to a closed surface of the charging cover 1, and after installation is completed, waterproof testing is performed.

[0042] The piezoelectric pressure sensor 7 is connected to a vehicle control system through a data acquisition system, and during installation, a wire is protected by a waterproof sleeve, a signal transmission distance between the sensor and the data acquisition system is not more than 1m, and signal stability is ensured.

[0043] The charging cover 1 is connected to the jack base 2 through a hinge, the hinge is made of stainless steel, and during installation, rust-proof oil is applied, the convex block 6 cooperates with the bayonet 4 when the charging cover 1 is closed, and a closing signal is triggered by the charging cover switch 3.

[0044] A charging cover detection method based on a pressure sensor, the detection method including a pressure signal acquisition process, a signal processing process, a charging gun state judgment process, and an adaptive correction process; the pressure signal acquisition process acquires pressure signals FN1 and FN2 generated when the charging cover 1 is closed in real time through two piezoelectric pressure sensors 7 and transmits the pressure signals to a data acquisition system; the signal processing process converts the pressure signals into voltage signals by using a DLF series channel charge amplifier, performs filtering and standardization processing through a DASP signal analyzer, and dynamically corrects temperature influences in combination with a temperature compensation module; the charging gun state judgment process comprehensively judges according to a CC resistance detection result and the pressure signals: if the CC resistance is not detected and the two piezoelectric pressure sensors 7 do not detect pressure signals, the charging gun state is disconnected; if the CC resistance is not detected but any sensor detects a pressure signal, the charging gun state is disconnected; if the CC resistance is not detected and the two sensors both detect pressure signals, the charging gun state is connected; if the CC resistance is detected and any sensor detects a pressure signal, the charging gun state is connected; if the CC resistance is detected and the two sensors do not detect pressure signals, the charging gun state is disconnected; and the adaptive correction process updates a pressure threshold value every 72 hours through historical data analysis, reduces environmental interference, and improves detection accuracy, and when the charging gun state is disconnected, the vehicle control system allows switching to a high-voltage state.

[0045] The sealing gasket 8 has two functions: one is to prevent water from entering the charging interface and damaging the charging interface when the charging cover is closed; the other is to provide a buffer effect when an external force is applied, thereby avoiding direct contact between the force and the sensor and damaging the sensor.

[0046] When the vehicle charging is completed, the user disconnects the charging gun and the charging cover is in a closed state, as shown in Figure 4 When the charging cover is closed, the charging cover is tightly fitted with the socket base, at this time a certain pressure is generated, the surface of the buffer gasket bears the external force from the charging cover, and the buffer gasket further transmits the pressure to the piezoelectric sensor. The piezoelectric sensor refers to the type of pressure sensor, and the two piezoelectric sensors bear forces FN1 and FN2 respectively, FN1 and FN2 are equal in size and same in direction. If the user does not disconnect the charging gun after the vehicle charging is completed, the charging cover is in a state as shown in Figure 2 The piezoelectric sensor will not be subjected to any force from the charging cover. Therefore, in the present application, whether the piezoelectric sensor bears the pressure from the charging cover is used as a standard for judging whether the charging gun is disconnected.

[0047] The piezoelectric pressure sensor used in the present application has the advantages of simple structure, wide frequency band, high sensitivity, reliable operation, high signal-to-noise ratio, light weight and low price. The piezoelectric sensor is widely used in various industries. The piezoelectric sensor is used to measure force and non-electric physical quantities that can be converted into electricity. When the piezoelectric material is subjected to an external force, an electric charge is generated on its surface. After the electric charge is amplified by a charge amplifier and a measurement circuit and the impedance is converted, it becomes an electric quantity output proportional to the external force. Its working principle is shown in Figure 5

[0048] The force on the charging cover after it is closed is analyzed above. The piezoelectric pressure sensor 7 collects the force, converts it into a voltage signal through a special DLF series channel charge amplifier, and uses a data automatic acquisition system and a DASP signal analyzer to process the signal. The analyzed signal is transmitted to the control system of the vehicle for further analysis. Through comprehensive judgment with the CC resistor, it is determined whether the vehicle can be started or operated normally. The test system block diagram of the new energy electric vehicle charging gun is shown in Figure 6 As can be seen from Figure 6 , two pressure sensors 7 are used in the present application, which has the advantages that: first, multiple pressure sensors 6 in series can increase the output charge and improve the voltage sensitivity, avoiding the failure to sense the output signal due to the small pressure of the charging cover; second, avoiding the failure of the sensor, which leads to misjudgment of the charging gun connection state. When the two sensors are connected in series, the problem of misjudgment of the charging gun connection state due to the failure of the sensor is greatly reduced. ​

[0049] As Figure 6 shown when two piezoelectric sensors are connected in series, the accuracy of judging the connection state of the charging gun is improved, and the CC resistor is also judged to further accurately judge the connection state of the charging gun. It should be noted that Figure 6 piezoelectric sensor 1 and piezoelectric sensor 2 in the above embodiment correspond to one side pressure sensor 7 and the other side pressure sensor 7 respectively. During detection, piezoelectric sensor 1 and piezoelectric sensor 2 may lose signal. This state is considered as the same case as piezoelectric sensor 1 and piezoelectric sensor 2 not detecting pressure signal, and the processing method is the same. If the CC resistor is not detected and piezoelectric sensor 1 and piezoelectric sensor 2 do not detect pressure signal, the vehicle can be normally operated to high voltage state or normal response operation; if the CC resistor is not detected and piezoelectric sensor 2 does not detect pressure signal, piezoelectric sensor 1 detects pressure signal, then it is confirmed that the charging gun state is disconnected; if the CC resistor is not detected and piezoelectric sensor 1 does not detect pressure signal, piezoelectric sensor 2 detects pressure signal, then it is confirmed that the charging gun state is disconnected; if the CC resistor is not detected, but piezoelectric sensor 1 and piezoelectric sensor 2 detect pressure signal, then it is confirmed that the charging gun state is connected; if the CC resistor is detected, but piezoelectric sensor 1 and piezoelectric sensor 2 do not detect pressure signal, then it is confirmed that the charging gun state is disconnected; if the CC resistor is detected and piezoelectric sensor 1 detects pressure signal, piezoelectric sensor 2 does not detect pressure signal, then it is confirmed that the charging gun state is connected; if the CC resistor is detected and piezoelectric sensor 2 detects pressure signal, piezoelectric sensor 1 does not detect pressure signal, then it is confirmed that the charging gun state is connected; if the CC resistor is detected and piezoelectric sensor 1 and piezoelectric sensor 2 both detect pressure signal, then it is confirmed that the charging gun state is connected. Through double judgment of CC resistor and piezoelectric sensor, the connection state of the charging gun is ensured. If the charging gun state is connected, the vehicle cannot be operated to high voltage state; if the charging gun state is disconnected, the vehicle can be normally operated to high voltage state, realizing protection of the charging gun and charging interface. In summary, the detection scheme can avoid the situation that the vehicle connection of the gun is misreported by using a single detection method.

[0050] It should be noted that piezoelectric sensor: a sensor based on piezoelectric effect. Its sensitive element is made of piezoelectric material. The surface of the piezoelectric material produces electric charge after being stressed. This electric charge is amplified and impedance converted by charge amplifier and measurement circuit to become an electric quantity output proportional to the external force. Piezoelectric sensor is used to measure force and non-electric physical quantity that can be converted into electricity. Specific embodiment two:

[0052] As Figures 1 to 6 shown, the following is the complete implementation of the above embodiment:

[0053] The following is a complete operation mode description of the pressure sensor-based charging cover detection structure and method. The system includes a charging cover 1 and a jack base 2, which are connected by a hinge to allow the charging cover to be freely opened and closed. The front of the charging cover is provided with a semicircular protrusion 6 that matches the bayonet 4 opened at the top of the jack base. The bottom of the bayonet is fixed with a charging cover switch 3 by a screw, which is triggered when the protrusion is closed. The inside of the jack base is installed with a circular ring-shaped sealing gasket 8 by a buckle, which provides waterproof sealing when the charging cover is closed to protect the internal components.

[0054] Two piezoelectric pressure sensors 7 are embedded on both sides of the sealing gasket 8 near the bottom, with the sensor surface flush with the gasket. They are connected to the data acquisition system through waterproof sleeve wires, with a transmission distance of no more than 1 meter to ensure signal stability. Seven contacts 5 are welded to the bottom of the jack base, which are vehicle socket contacts, control guide CP, neutral N, AC power L1, L2, L3, and protective ground PE, arranged in a circular array. A temperature compensation module, including a thermistor, is installed on the inner wall of the jack base by adhesion, connected to the data acquisition system to adjust the sensor sensitivity within the range of -20°C to 60°C, with an error of within ±0.1°C to reduce the influence of environmental temperature. A waterproof, breathable, and dustproof film is pasted around the bayonet between the charging cover and the jack base, which is pressed tightly by the protrusion 6 when closed, improving the durability of the interface. The power management module is fixed to the bottom of the base by screws, designed with low power consumption (standby power consumption below 10 mW), providing 5V to 12V voltage with overvoltage and short circuit protection, powering the sensors and switches.

[0055] During installation, the jack base 2 is fixed to the vehicle charging interface by fastening bolts to ensure that it is flush with the vehicle shell, and the sealing gasket is tightly attached to the closed surface of the charging cover. After completion, waterproof testing is performed. The stainless steel hinge is coated with anti-rust oil to support the movement of the charging cover, and the switch is triggered when the protrusion and the bayonet are matched when closed. Figure 4 During operation, the user disconnects the charging gun after the vehicle charging is completed and closes the charging cover (as shown in reference

[0056] The control system combines the CC resistance detection result to judge the charging gun state: if the CC resistance is not detected and there is no pressure signal of the two sensors, the gun is disconnected, and the high voltage is allowed to activate; if the CC resistance is not detected but there is pressure in any sensor or both sensors have pressure without CC, the gun is connected, and the high voltage is prohibited; if the CC resistance is detected and there is pressure in any sensor, the gun is connected; if the CC resistance is detected without pressure, the gun is disconnected. The adaptive correction process analyzes historical data every 72 hours to optimize the pressure threshold, reduce environmental interference, and improve accuracy. The sealing gasket not only prevents water and protects the interface, but also buffers external force to protect the sensor. The two sensors are connected in series to increase data output, enhance sensitivity, and avoid single failure misjudgment. The sensor signal loss is considered as no pressure, consistent with the disconnection logic. Double judgment (pressure + CC resistance) prevents single detection failure, ensures that the gun is disconnected before high voltage is enabled, and guarantees safety and reliability. Embodiment Three:

[0058] As shown in the following, the following are supplementary implementation details of the detection method and device: Figures 1 to 6

[0059] Hardware parameters:

[0060] Charging cover 1: ABS engineering plastic, thickness 3mm, weight 150g, temperature resistance range -30℃ to 80℃, size 150mmx100mmx20mm.

[0061] Receptacle base 2: aluminum alloy material, size 160mmx110mmx30mm, weight 200g, corrosion-resistant coating, mounting hole diameter M6.

[0062] Piezoelectric pressure sensor 7: model Kistler601A, sensitivity 20pC / N, measurement range 0-100N, response frequency 0-10kHz, working temperature -40℃ to 120℃, power supply 5V.

[0063] Charging cover switch 3: micro switch model Omron D2F, rated current 0.1A, voltage 5V, service life 1 million times, size 12mmx6mmx5mm.

[0064] Sealing gasket 8: silicone material, thickness 5mm, inner diameter 120mm, outer diameter 140mm, hardness 50 Shore A, waterproof level IP67.

[0065] Contact 5: copper gold plating, diameter 6mm, length 15mm, current capacity 20A, resistance <0.01Ω.

[0066] Temperature compensation module: thermistor model NTCMF52, resistance 10kΩ±1% at 25℃, response time <10s, size 2mmx2mm.

[0067] ​Dustproof film: PTFE material, thickness 0.1 mm, air permeability 1.5 L / m 2 / s, pressure resistance 0.5 bar.

[0068] Power management module: Model TITPS62825, output 5-12V, maximum current 2A, standby power consumption <10mW, size 3mmx3mm.

[0069] Data acquisition system: NIUSB-6009, sampling rate 10kS / s, input range ±10V, interface USB2.0.

[0070] Algorithm implementation:

[0071] The algorithm implementation starts with real-time collection of pressure signals generated by the piezoelectric pressure sensor 7 when the charging cover 1 is closed. The sensor converts mechanical pressure into electric charge. The data is first amplified by a DLF series charge amplifier with a gain of 100 to enhance signal strength, and then enters a DASP signal analyzer for low-pass filtering (cutoff frequency 500Hz) to effectively remove high-frequency noise and ensure data purity. Next, the temperature compensation module 9 monitors the internal temperature of the jack base 2 in real time, dynamically adjusts the sensor sensitivity based on the thermistor data, and corrects the deviation caused by environmental temperature changes from -20°C to 60°C. The processed signal is transmitted to the NIUSB-6009 data acquisition system, which is standardized as two pressure values FN1 and FN2 with a sampling rate of 10kS / s.

[0072] At the same time, the system reads the state signal of the CC resistor in parallel, and integrates the pressure data and CC resistance results through the data acquisition system. The judgment logic is executed in the following steps: first, check if the CC resistor detects a signal, if there is no CC signal, further analyze FN1 and FN2; if the pressure values of both sensors are lower than the preset threshold (for example, 5N), it is determined that the charging gun is in the disconnected state; if any sensor detects pressure (>5N) or both have pressure, combine the CC state, if the CC detects a signal, it is in the connected state, otherwise it is disconnected. Historical data is updated every 72 hours by weighted average method, the weight is based on the proportion of recent 24 hours data 60%, 48-72 hours 40%, to optimize environmental adaptability. The final result is transmitted to the vehicle control system through CAN bus to determine whether to allow high voltage activation.

[0073] Abnormal processing:

[0074] When the piezoelectric pressure sensor 7 detects signal loss or output anomaly (deviation > 10%), the system triggers a self-diagnostic mode, records the abnormal time and sensor number, switches to a backup mode relying only on CC resistance judgment. When the sensor fails, the warning light is on (red LED, 2Hz flashing), and the fault code is sent to the vehicle control system through the CAN bus. If the temperature compensation module exceeds the range (> 60℃ or <-20℃), the sampling frequency is automatically reduced to 1Hz to prevent data distortion. When the power management module detects overvoltage (> 12V) or short circuit, it will shut down the power for 5 seconds and then restart. After 3 times of abnormality, it will be locked and alarmed.

[0075] Maintenance process:

[0076] Check the wear of the sealing gasket 8 every month and replace it if necessary (replacement period 6-12 months). Clean the surface of the contact 5 every quarter, remove dust and wipe with alcohol, and ensure that the resistance is <0.01Ω. Calibrate the piezoelectric pressure sensor 7 and temperature compensation module every year using a standard pressure source (50N) and thermometer (accuracy 0.1℃), replace if deviation >5%. Replace the battery or check the circuit board aging of the power management module every two years. Maintenance records are archived and uploaded to the vehicle management system, and contact authorized service providers (response time <24h) in case of abnormality.

[0077] This solution meets the IEC61851-1:2017 (Electric Vehicle Conduction Charging System) and ISO15118-1:2019 (Vehicle-to-Grid Communication) standards, with waterproof and dustproof up to IP67 (IEC60529). Electromagnetic compatibility meets CISPR25 Class3, with radiation interference <50dBμV / m. Safety certification passes CE and RoHS, and materials are non-toxic and harmless. Data privacy complies with GDPR and CCPA, sensor data is encrypted transmission (AES-256), and only vehicle control system access is allowed. Product labeling includes production batch number, serial number and usage instructions, with a 2-year warranty.

[0078] The above content is based on the characteristics of the solution to ensure that hardware, algorithms, exception handling, maintenance and compliance fully cover the actual application requirements.

[0079] It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting; it is not intended to exclude myriad other embodiments of the present application that other inventors can develop based on the same general inventive concepts embodied by the described embodiments. That is, although the present application is described in terms of particular embodiments and implementations, it is to be understood that the terminology used is for the purpose of descriptive clarity and that it is intended to be limited only by the words of the patent claims. A reference to an aspect of the present application employing a particular aspect, feature or structure of the described embodiments is not to be interpreted as an indication that all or even any aspects of the present application have such feature or structure in some way.

[0080] While the embodiments of the application have been shown and described herein, it will be understood by those skilled in the art that many changes, modifications, substitutions and alterations to these embodiments can be made without departing from the spirit and scope of the present application, which is defined by the appended claims and their equivalents.

Claims

1. A pressure sensor-based charging cover detection structure, comprising a charging cover (1) and a socket base (2), characterized in that: The socket base (2) is movably connected to the charging cover (1) via a hinge; a semicircular protrusion (6) is provided on the front of the charging cover (1); a bayonet (4) adapted to the protrusion (6) is provided on the top of the front of the socket base (2); a charging cover switch (3) is installed at the bottom of the bayonet (4); the charging cover switch (3) is fixed to the bottom of the bayonet (4) via a screw; a circular sealing gasket (8) is clamped inside the socket base (2); and the sealing gasket (8) is connected to the inner wall of the socket base (2) via a buckle.

2. The pressure sensor-based charging cover detection structure according to claim 1, characterized in that: Piezoelectric pressure sensors (7) are installed near the bottom of both sides of the sealing gasket (8). The piezoelectric pressure sensors (7) are fixed by wires and embedded in the sealing gasket (8), and the sensor surface is flush with the sealing gasket (8). Seven contacts (5) are provided at the bottom of the jack base (2). The seven contacts (5) are respectively a vehicle socket contact, a control guide CP, a neutral line N, an AC power supply L1, an AC power supply L2, an AC power supply L3 and a protective ground PE. The contacts (5) are fixed to the bottom of the jack base (2) by welding and are distributed in a circular array.

3. The pressure sensor-based charging cover detection structure according to claim 1, characterized in that: A temperature compensation module is also provided in the jack base (2), and the temperature compensation module includes a thermistor, which is mounted on the inner wall of the jack base (2) by bonding and connected to a data acquisition system. The temperature compensation range is -20°C to 60°C, and the error is controlled within ±0.1°C.

4. The pressure sensor-based charging cover detection structure according to claim 1, characterized in that: A dustproof membrane is provided between the charging cover (1) and the socket base (2). The dustproof membrane is made of a waterproof and breathable material and is fixed around the bayonet (4) by adhesive. When the charging cover (1) is closed, the convex block (6) presses the charging cover tightly to ensure a sealing effect.

5. The pressure sensor-based charging cover detection structure according to claim 1, characterized in that: A power management module (11) is provided in the socket base (2), which is fixed to the bottom of the socket base (2) by screws. The power management module adopts a low-power design to power the piezoelectric pressure sensor (7) and the charging cover switch (3), has overvoltage protection and short-circuit protection functions, an operating voltage range of 5V to 12V, and a standby power consumption of less than 10mW.

6. The pressure sensor-based charging cover detection structure according to claim 1, characterized in that: The socket base (2) is installed at the vehicle charging interface position by fastening bolts. During installation, it is ensured that the socket base (2) is flush with the vehicle housing and the sealing gasket (8) is tightly fitted with the closing surface of the charging cover (1). After installation, a waterproof test is performed.

7. The pressure sensor-based charging cover detection structure according to claim 1, characterized in that: The piezoelectric pressure sensor (7) is connected to the vehicle control system via a data acquisition system. During installation, the wire is protected by a waterproof casing. The signal transmission distance between the sensor and the data acquisition system does not exceed 1 meter, ensuring signal stability.

8. The pressure sensor-based charging cover detection structure according to claim 1, characterized in that: The charging cover (1) is connected to the socket base (2) via a hinge. The hinge is made of stainless steel and is smeared with anti-rust oil during installation. When the charging cover (1) is closed, the protrusion (6) cooperates with the bayonet (4), triggering the charging cover switch (3) to complete the closing signal.

9. A pressure sensor-based charging cover detection structure according to any one of claims 1 to 8, wherein the detection method for the pressure sensor-based charging cover detection structure is characterized in that: The detection method includes a pressure signal acquisition process, a signal processing process, a charging gun state judgment process and an adaptive correction process; the pressure signal acquisition process uses two piezoelectric pressure sensors (7) to collect pressure signals FN1 and FN2 generated when the charging cover (1) is closed in real time, and transmits them to a data acquisition system; the signal processing process uses a DLF series channel charge amplifier to convert the pressure signal into a voltage signal, performs filtering and standardization processing through a DASP signal analyzer, and dynamically corrects the temperature influence in combination with a temperature compensation module; the charging gun state judgment process makes a comprehensive judgment based on the CC resistance detection result and the pressure signal: if the CC resistance is not detected and the two piezoelectric pressure sensors (7) do not detect a pressure signal, the charging gun state is disconnected; If the CC resistance is not detected but any sensor detects a pressure signal, the charging gun status is disconnected; If the CC resistance is not detected and both sensors detect pressure signals, the charging gun status is connected; If the CC resistance is detected and any sensor detects a pressure signal, the charging gun status is connected; If the CC resistance is detected and neither sensor detects a pressure signal, the charging gun is in disconnected state. The adaptive correction process updates the pressure threshold every 72 hours through historical data analysis to reduce environmental interference and improve detection accuracy. When the charging gun is disconnected, the vehicle control system allows switching to high voltage.

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